Mechanical engineering design evaluation & estimating software.

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EngineerOnLine Ltd also supply stainless steel tanks and vessels, tank estimating & design evaluation software,
with online budget prices for tanks.

The features of TankGenii include:

An extremely user friendly and intuitive, step by step format.
Everything is defined by text data. As each piece is input, the place for entering the next piece appears. Many are selected from a drop-down list, and if anything is inappropriate the program says so and won't allow progress until the error is corrected. You don't have to calculate anything. Tank-Genii does it all.


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A separate database for storing worked examples. 
This extracts up to 225 pieces of data from TankGenii and allows you to store it as a single line of data. This feature is particularly useful for analysing the cost of various configurations for an individual tank and as the records build up over time, the quote success rates, against the parameters applying at the time.

The integrated, smart database of materials costs.
There are three Derivatives used for each cost offered, which you can also override at the program interface.
1) Unit Rates that you can enter at any time, for any material, together with the date that you enter it. These would be the known best price at which the material can be purchased, inclusive of any duty or taxes. If this data is input and the date that it is entered is less than 90 days old, the database offers this price. For countries outside the USA, there is also provision to enter a US$ price which the program will use, if either the known purchase cost has not been entered or once again, the entry date is less than 90 days old. This price is automatically adjusted to the foreign exchange rate that you set.
2) International Base Rates. TankGenii is formatted for use in any country. There are a number of "International Base Rates" for the common materials of construction which when factored by the foreign exchange rate of a particular country against the US Dollar, will ascertain the price that an importing agent will pay. If no known purchase cost has been entered or the date of entry exceeds 90 days old, the database uses these International Base Rates together with the foreign exchange rate to derive the price, used. These rates can be used to derive prices previously unencountered. Hence, if a quotation is prepared using the International Base Rates, and provided these are current, the price should be valid. A reasonable margin for an importing agent is allowed. If circumstances prevent obtaining a current purchase cost at the particular time that you are preparing a quote (after hours, or en route perhaps), your quotation will include costs that are reasonable.
3) Formula. For items other than basic materials (insulation, agitator drives, access ladders etc) if no known purchase cost, or US$ rate has been entered, and/or the date of entry exceeds 90 days, there are derived formulae that will deduce a price, usually but not in every case, based on a constant related to the current cost of 304. You may derive your own constant and modify the formula.
The database checks for these derivatives in the order shown as being the degrading order of likely accuracy and as previously mentioned, offers it for use and finally, you choose to use or override it when using the program.

A database for storing and calling up separate "Stock" items, if and as required.
Costs assigned to any items stored, are automatically updated as time passes.

A separate "Budget Pricer" 
To instantly calculate a budget price for an L grade stainless tank: 
If under 10,000 liters, (2,642 US gallons) a 400 (16") manway, 2 x 80mm (3") nozzles, an insect-proof vent, cone top and bottom with the welds strip polished 180 grit one side and if over 10,000 liters, a 500 (20") manway, plus 2 extra 150mm (6") nozzles are automatically allowed for. Support system is based on Sched10S legs, with |/\| bracing if over 10,000 liters

The automatic design calculations.
Before any costing can be done, the weight of material required must be known, so TankGenii calculates all the required thicknesses according to various design codes, including API. It checks each result against a workshop specific, minimum thickness that you nominate and selects the most conservative.

Constant checking for design inefficiencies.
Formulas by nature produce precise results. They cannot consider whether a calculated thickness is available.
TankGenii compares the calculated thicknesses with those that are commercially available and uses the next conforming size. It then checks for inefficiencies caused by any particular design parameter just forcing a heavier gauge and suggests alternatives if appropriate.
A typical example is a cone top or bottom. The cone angle is a significant factor in thickness calculations, particularly as the angle approaches that commonly used for tanks. Yet changing the design from say 20o of slope to 21o could well change the required thickness from 3.1mm to 2.9mm and the common sheet thickness range steps from 4.0mm to 3.0mm. See also the design notes regarding the likely cost effect. Few if any workshops could be expected to guarantee a 1o variation of slope on say a 3 meter diameter tank and I doubt it could be measured within acceptable commercial constraints, but the design will conform.

Automatic inclusion of unsalvageable waste material.
The amount of unsalvageable waste varies according to the shape being formed. If the strakes of the barrel are cut, accurately first time, from coil stock the amount is minimal and certainly a lot less than occurs when forming say a cone. Therefore the wastage factor varies from tank to tank, depending on the diameter to height ratio. Tank-Genii analyses cones and flat bottoms, in depth. On larger tanks, it allows for pyramid-stepping the blanks, and on cones it calculates the amount salvaged from the wedge, whenever that exceeds a meter squared.

Automatic inclusion of a consumables cost, calculated to suit the materials of construction.
Consumables for austenitic 304 and 316 are usually the same but variations occur when other materials are used, both in the welding and dressing or polishing. Unless these more exotic grades are common for the workshop which is unusual, even the quality control systems must be more stringent. The consumables rate for non common grades must be adjusted accordingly. See also the stainless notes page.
The automatic inclusion of bracing to any legs when appropriate, for seismic or high wind load conditions.
If legs are specified, not only are they analysed for buckling and bracing included when necessary, but the resultant stress relative to that allowable is reported alongside the cost. Thus, various options can be instantly checked for cost effectiveness. A skirt option can be similarly checked.

The automatic inclusion of job start-up hours.

Automatic compensation for numbers off.
To acknowledge the effect of building more than one, TankGenii adjusts the calculated labour hours according to a derived hyperbolic function. The program is intended for custom built tanks where the greatest variation occurs over the first two or three repeats and after about ten, gives only a very small differential.

The system of analysing every component into separate labour functions according to the requirements of each tank.
To calculate labour hours, TankGenii analyses each tank component by five types of labour operation and each component type is treated separately. (Barrel strakes are much simpler to mark out, cut and form than the ends, and cone ends are different to dome or flat ends) Thus each component is separately analysed for-
1. Marking out and cutting. Both weight and bulk are taken into consideration.
2. Forming. Weight, bulk and the degree of deformation relative to thickness are taken in to consideration.
3. Tacking up. Weight and bulk are taken in to consideration.
4. Welding. The appropriate method and weld profile for the thickness are used to determine an appropriate (not theoretical) deposit rate, which is applied to a precisely calculated weld length.
5. Weld finishing (passivating or grinding and polishing)
If an open topped tank is specified, an edge reinforcing ring is selected according to size of the tank and analysed for its labour. Similarly, if a flat top is fitted, a reinforcing bridge, sized according to the span, is allowed for when appropriate, and if an agitator is fitted the bridge size is increased accordingly.

Flexibility that allows its use over a full range of applications.
Every result that is derived or data that is used is reported and can be overridden at your discretion. This includes the unit material costs, thicknesses and labour hours. On larger tanks, the thicknesses vary up the barrel wall, but if for whatever reason you have need to disregard any or all of these, it is simply a matter of inputting what you want. TankGenii is not intended for pressure vessels, but a user has quoted several vessels subject to full vacuum, for which the required thicknesses were given. These were input accordingly and a completely successful project resulted, demonstrating that both the labour formulae, and the system of analysing are principally correct and accurate. TankGenii can be used configured as supplied, or it can be "fine tuned" and since the quoting function is so fundamental to the ongoing viability of all workshops, this option is recommended for workshop users.
Click here to view a copy of the demo evaluation email. This covers even more features.
Click TankGenii to return there,  or send for your free TankGenii evaluation version.

 

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